4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual - part 20

21. REMOVE AIR TUBE, ASV (FOR A/C) AND VACUUM

PIPE
(a) (w/ A/C)
Disconnect the ASV connector.
(b) Disconnect the following hoses:

(1) PS air hose from intake manifold
(2) Two air hoses from air tube
(3) (w/ A/C)

Air– hose from intake manifold

(4) Vacuum hose from gas filter
(5) Vacuum hose from fuel pressure regulator

(c) Remove the four bolts, vacuum hose bracket, the

air tube and ASV assembly.

(d) Remove the bolt and vacuum pipe.

22. DISCONNECT ENGINE WIRE GROUND STRAPS AND

CONNECTORS
(a) Two engine ground straps from intake manifold
(b) Knock sensor connector
(c) VSV connector for EGR

23. REMOVE VSV FOR EGR

24. REMOVE ACCELERATOR BRACKET
25. REMOVE INTAKE MANIFOLD

(a) Disconnect the PCV hose from the PCV valve.
(b) Disconnect the two wire clamps from the wire

brackets.

20. DISCONNECT VACUUM HOSES

(a) Vacuum sensor hose from gas filter
(b) Brake booster vacuum hose from intake manifold
(c) (w/ Cruise Control System (w/o ABS))
Actuator vacuum hose from intake manifold

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ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–154

(e) Remove the six bolts, two nuts, intake manifold and

gasket.

26. REMOVE DELIVERY PIPE AND INJECTORS

(See steps 16 and 17 on page 

FI–173

)

27. REMOVE CAMSHAFT TIMING PULLEY

(See steps 2 and 6to17 on pages 

EM–67

 to 70)

28. REMOVE NO.1 IDLER PULLEY AND TENSION SPRING

(See step 23 on page 

EM–72

)

30. REMOVE ENGINE HANGERS

Remove the bolt and engine hanger. Remove the two
engine hangers. Remove the ground strap.

31. REMOVE ALTERNATOR BRACKET

Remove the three bolts and alternator bracket.

32. REMOVE OIL PRESSURE SWITCH

NOTICE:

•

Support the timing belt, so the meshing of the
crankshaft timing pulley and timing belt does
not shift.

•

Be careful not to drop anything inside the timing
belt cover.

•

Do not allow the belt to come into contact with
oil, water or dust.

(c) Remove the bolt, and disconnect the engine wire

protector from the intake manifold.

(d) Remove the four bolts, connector bracket (CALIF.

only) and two manifold stays.

29. REMOVE NO.3 TIMING BELT COVER

Remove the four bolts and timing belt cover.

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ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–155

35. REMOVE CAMSHAFTS

NOTICE: Since the thrust clearance of the camshaft
is small, the camshaft must be kept level while it is

being removed. If the camshaft is not kept level, the

portion of the cylinder head receiving the shaft thrust

may crack or be damaged, causing the camshaft to
seize or break. To avoid this, the following steps
should be carried out.

A. Remove exhaust camshaft

(a) Set the knock pin of the intake camshaft at 10 –45

°

BTDC of camshaft angle.
HINT: The above angle allows No.2 and No.4 cylinder
cam lobes of the exhaust camshaft to push their valve
lifters evenly.

HINT: Arrange the grommets in correct order, so
that they can be reinstalled into their original posi-
tions. This minimizes any possibility of oil leakage
due to reuse of grommets.

33. REMOVE CYLINDER HEAD COVER

Remove the four nuts, grommets, head cover and gasket.

34. REMOVE HIGH–TENSION CORD CLAMP AND PCV

VALVE FROM CYLINDER HEAD COVER

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ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–156

(f) Alternately loosen and remove the two bolts on the

No.3 bearing cap.

HINT:

•

As the two No.3 bearing cap bolts are loosened,
make sure that the camshaft is lifted out straight
and level.

•

If the camshaft is not being lifted out straight
and level, retighten the two No.3 bearing cap
bolts. Then reverse the order of above steps
from (f) to (a) and reset the knock pin of the in-
take camshaft at 10 – 45

°

 BTDC, and repeat

steps from (b) to (f) once again.

NOTICE: Do not pry on or attempt to force the cam-

shaft with a tool or other object.

(g) Remove the No.3 bearing cap and exhaust camshaft.

B. Remove intake camshaft

(a) Set the knock pin of the intake camshaft at 80 –115

°

BTDC of camshaft angle.

HINT: The above angle allows the No.1 and No.3 cylin-
der cam lobes of intake camshaft to push their valve
lifters evenly.

(b) Secure the exhaust camshaft sub–gear to drive

gear with a service bolt.

Recommended service bolt:

Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16 – 20 mm (0.63 – 0.79 in.)

HINT: When removing the camshaft, make sure
that the torsional spring force of the sub–gear has
been eliminated by the above operation.

(d) Uniformly loosen and remove the six bolts on the

No.1, No. 2 and No.4 bearing caps in several
passes in the sequence shown.

NOTICE: Do not remove the No.3 bearing cap

bolts at this stage.

(e) Remove the No.1, No.2 and No.4 bearing caps.

(c) Remove the two bolts and rear bearing cap.

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ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–157

(e) Alternately loosen and remove the two bolts on the

No.2 bearing cap.

HINT:

•

As the two No.2 bearing cap bolts are loos-
ened, make sure that the camshaft is lifted out
straight and level, after breaking adhesion on
the front bearing cap.

•

If the camshaft is not being lifted out straight
and level, retighten the two No.2 bearing cap
bolts. Reverse the order of above steps from
(e) to (a) and reset the knock pin of the intake
camshaft at 80 – 115

°

 BTDC, and repeat steps

from (b) to (e) once again.

NOTICE: Do not pry on or attempt to force the cam-

shaft with a tool or other object.

(f) Remove the No.2 bearing cap and camshaft.

36. DISASSEMBLE EXHAUST CAMSHAFT

(a) Mount the hexagon wrench head portion of the cam-

shaft in a vise.

NOTICE: Be careful not to damage the camshaft.

(c) Uniformly loosen and remove the bolts on the

No.1, No.3 and No.4 bearing caps in several
passes in the sequence shown.

NOTICE: Do not remove the No.2 bearing cap

bolts at this stage.

(d) Remove the No.1, No.3 and No.4 bearing caps.

(b) Insert a service bolt (A) into the service hole of the

camshaft sub–gear.

(c) Using a screwdriver, turn the sub–gear clockwise,

and remove the service bolt (B).

NOTICE: Be careful not to damage the camshaft.

(b) Remove the two bolts, front bearing cap and oil

seal.

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ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–158

(c) Lift the cylinder head from the dowels on the cyl-
inder block, and place the cylinder head on wooden
blocks on a bench.
HINT: If the cylinder head is off, pry between the
cylinder head and cylinder block with a screwdriver.
NOTICE: Be careful not to damage the contact sur-

faces of the cylinder head and cylinder block.

37. REMOVE CYLINDER HEAD

(a) Uniformly loosen and remove the ten cylinder head

bolts in several passes in the sequence shown.

NOTICE: Cylinder head warpage or cracking could

result from removing bolts in incorrect order.

(b) Remove the ten plate washers.

(e) Remove the following parts:

(1) Wave washer
(2) Camshaft sub–gear
(3) Camshaft gear spring

(d) Using snap ring pliers, remove the snap ring.

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ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–159

2. REMOVE VALVES

(a) Using SST, compress the valve spring and remove

the two keepers.

SST 09202–70010
(b) Remove the spring retainer, valve spring, valve and

spring seat.

DISASSEMBLY OF CYLINDER HEAD

(See page 

EM–150

)

1. REMOVE VALVE LIFTERS AND SHIMS

HINT: Arrange the valves, valve springs, spring
seats and spring retainers in correct order.

HINT: Arrange the valve lifters and shims in correct
order.

(c) Using needle–nose pliers, remove the oil seal.

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ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–160

INSPECTION, CLEANING AND REPAIR
OF CYLINDER HEAD COMPONENTS

1. CLEAN TOP SURFACES OF PISTONS AND CYLINDER

BLOCK
(a) Turn the crankshaft, and bring each piston to top

dead center (TDC). Using a gasket scraper, remove
all the carbon from the piston top surface.

2. CLEAN CYLINDER HEAD
A. Remove gasket material

Using a gasket scraper, remove all the gasket material
from the surface contacting the cylinder block.
NOTICE: Be careful not to scratch the cylinder block

contact surface.

(b) Using a gasket scraper, remove all the gasket

material from the surface contacting the cylin-
der head.

(c) Using compressed air, blow carbon and oil from

the
bolt holes.

CAUTION: Protect your eyes when using high–

compressed air.

B. Clean combustion chambers

Using a wire brush, remove all the carbon from the
combustion chambers.
NOTICE: Be careful not to scratch the cylinder block

contact surface.

C. Clean valve guide bushings

Using a valve guide bushing brush and solvent, clean
all the guide bushings.

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ENGINE MECHANICAL

Cylinder Head (5S–FE)

EM–161